EDM MACHINING PROCESS

Introduction EDM is a non-conventional manufacturing process. In this process, the material is removed by erosive action of electric discharges occurring between a tool electrode and work piece based on the fact that no tool force is generated during machining. Both work piece and tool electrode are submerged in a solution called dielectric. The mechanical characteristics of work piece and electrode are not a concern because the electrical energy is converted into thermal energy causing melting of the material. EDM process Allows the machining of hard materials and more complex shapes which cannot be processed by other conventional methods. The EDM process is normally applied to mould and die making. Compared to conventional machining method, the material removal rate of this machining remains rather low . Spark gap and material removal due to one pulse in EDM process EDM is a process of removing material in a closely controlled manner from an electrically conductive material immersed in a liquid dielectric by a series of randomly distributed discrete electrical sparks or discharges. Non-conducting materials cannot act directly on electrode to achieve EDM. In order to machine these materials with EDM, the conditions that electrical discharges can be produced on their surface must be created. Mechanism of Material Removal In EDM, The removal of material is based upon the electro-discharge erosion (EDE) effect of electric sparks occurring between two electrodes that are separated by a dielectric liquid. Metal removal takes place as a result of the generation of extremely high temperatures generated by the high intensity discharges that melt and evaporate the two electrodes. EDM components. Direct-current power is supplied to the circuit in pulses that can be approximated by a square wave. Ideally, each pulse creates a spark. Each spark occurs where the resistance is smallest, usually near the last spark. The erosion occurs over the surface of the electrode and work piece interface. The square wave and plotting current against time are the basic common terminology of the EDM power supply. The variables are on-time, off-time, and peak current. A series of voltage pulses of magnitude about 20 to 120 V and frequency on the order of 50 kHz is applied between the two electrodes, which are separated by a small gap, typically 0.01 to 0.5mm. When using RC generators, the voltage pulses, are responsible for material removal. Typical EDM pulse current train for controlled pulse generator. Variation in voltage with time using an RC generator. The selection of supply voltage is

a compromise between several factors, for example, size of equipment, safety of operation, etc. The D.C. supply voltage used in EDM machines ranges between 30 to 200V. Power supplies are rated in amperes and range from 10 to 1000A. A pulsed D.C. supply was used to test the effect of highfrequency pulsed current. To find experimentally the amount of operational energy used to record the current between the anode and the cathode during operation. Ohm's law state is used : V = I R . (1) where V voltage is in Volts, current I is in Amps, and resistance R is in Ohms. The resistance between the anode and cathode was measured at approximately200 ohms. As the different variables were changed, data were recorded for the corresponding current changes. Again applying Ohm's law : P = V I . (2) where P is power in Watts. Substituting equation (1) into (2) yields: P = I2 R (3) And current density law states that: S= where S is current density in A/ mm2 and A is area of machining (mm2). When the electrons and the positive ions reach the anode and cathode, they give up their kinetic energy in the form of heat. Temperature of about 8000 to 12,000C or as high as 20,000C and heat fluxes up to 1017 W/m2 are reached when the pulsating direct current supply occurs at the rate of approximately 20,000-30,000Hz . With a very short time spark of typically between 0.1 to 2000s the temperature of the electrodes can be raised locally to more than their normal boiling points. Owing to the evaporation of the dielectric, the pressure on the plasma channel rises rapidly to values as high as 200 atmospheres. Such great pressures prevent the evaporation of the superheated metal . EDM consists of generating spark discharge between the tool and the Work piece immersed in a dielectric liquid. At the early stages of process, due to very low electrical current of electrons passing through the liquid dielectric from the negative electrode towards the positive pole, very small bubbles are created within the gap between the closest opposing peaks of roughness of the electrodes.